Ekoterm GP sc Series, GP 25 sc, GP 32 sc, GP 20 18 sc Installation, Operation And Maintenance Manual

MANUAL

FOR INSTALLATION, OPERATION AND MAINTENANCE OF

AN AUTOMATED PELLET BURNER FROM SERIES

„GP XX SC”

www.greenecotherm.eu

Pellet burner GP xx sc 1

Manufacturer

Ekoterm Proekt EAD

Address

Phone

Fax

E-mail

Web site

Bulgaria, 6300 Haskovo, 67 Saedinenire blvd.

[phone]

[phone]

[e-mail]

www.ecotherm.bg

The manufacture company thanks you for your choice.

The manufacture company submits this manual to help the team that will install, adjust and
service the pellet burner, as well as to the customer that will operate it.

The manufacturing company requires that the technicians, performing the above mentioned
procedures, had successfully passed the product’s technical training.

Edition: 11 July 2017

Pellet burner GP xx sc 2

CONTENT

page.

1. USERS SAFETY INFORMATION. ................................................................................................................. 4

2. DESCRIPTION AND ADVANTAGES OF THE AUTOMATED PELLET BURNER „GP XX SC”. ................... 5

3. TECHNICAL DATA OF THE PELLET BURNER FROM SERIES „GP XX SC”. ............................................. 7

4. CONSTRUCTION DESCRIPTION OF THE PELLET BURNER “GP XX SC”. ............................................... 9

4.1. GENERAL CONDITIONS. ................................................................................................................... 9

5. MOUNTING AND INSTALLATION OF THE PELLET BURNER. ................................................................. 11

5.1. MAIN REQUIREMENTS FOR INSTALLATION OF A PELLET BURNER „GP XX SC”. .....................11

5.2. INSTALLATION OF THE PELLET BURNER. ....................................................................................11

5.3. OVERALL DIMENSIONS OF THE BURNER’S MAIN MODULE. .......................................................12

5.4. POSITIONING AND MOUNTING OF THE BURNER’S MODULES. ..................................................13

5.5. INFORMATION ABOUT INSTALLATION AVAILABILITIES OF PELLET BURNER „GP XX SC” AND

ITS CO-OPERATION WITH HOT WATER BOILERS. .....................................................................................14

6. INITIATION TO OPERATION OF THE PELLET BURNER „GP XX SC”...................................................... 15

6.1. MAIN REQUIREMENTS ABOUT THE USED FUEL TYPES. ............................................................15

6.2. INITIATION TO OPERATION OF A PELLET BURNER „GP XX SC”. ................................................15

6.2.1. INTERFACE PANEL OF AN AUTOMATED PELLET BURNER “GP XX SC”. .......................... 16

6.2.2. CONNECTING AND POWER SUPPLYING OF THE BURNER. .............................................. 16

6.2.3. SWITCHING ON THE PELLET BURNER FROM SERIES „GP XX SC”. .................................. 17

6.2.4. ALGORITHM OF OPERATION OF A PELLET BURNER „GP XX SC”. .................................... 18

6.2.5. OPERATIONAL PARAMETERS FOR ADJUSTMENT OF A PELLET BURNER „GP XX SC”. 19

6.2.6. DESCRIPTION OF THE PRIMARY MENU, THE METHODS OF STARTING AND

OPERATIONAL PARAMETERS ADJUSTMENT OF A PELLET BURNER „GP XX SC”. .................................. 20

6.2.7. BURNER ADJUSTMENTS ACCORDING TO THE CONSUMED HEATING OUTPUT. ........... 23

6.2.8. NOMINAL OPERATION MODE OF THE BURNER. ................................................................. 23

6.2.9. OPERATION MODES OF A PELLET BURNER FROM SERIES „GP XX SC”. ........................ 23

6.2.10. USER MENUS IN THE CONTROL MODULE OF A PELLET BURNER „GP XX SC”. .............. 25

6.2.11. MENU “EFFECT LEVEL”. ......................................................................................................... 25

6.2.12. ACTIVATION OF OPTION “OPERATION WITH HEAT ACCUMULATOR (BUFFER)”. ........... 27

6.3. ADJUSTMENT OF THE BURNER’S HEATING OUTPUT. ................................................................28

6.3.1. DECREASING THE BURNER’S HEATING OUTPUT. ............................................................. 28

6.3.2. INCREASING THE BURNER’S HEATING OUTPUT. ............................................................... 28

6.4. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES „GP XX SC”. ....................29

6.4.1 STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES „GP XX SC” THROUGH

THE SWITCH “START”. ...................................................................................................................................29

6.4.2. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES „GP XX SC” THROUGH

A MENU FROM ITS COTROLLER KEYBOARD. .............................................................................................29

6.5. SWITCHING OFF A PELLET BURNER FROM SERIES „GP XX SC” THROUGH EXTERNAL

MODULE, MANAGING ITS OPERATION. .......................................................................................................31

6.5.1. EMERGENCY SHUT DOWN OF A PELLET BURNER FROM SERIES „GP XX SC”. ............. 31

6.6. MENU DISPLAYING A LIST WITH THE LAST FAILURES, OCCURRED DURING OPERATION OF A

PELLET BURNER FROM SERIES „GP XX SC”. .............................................................................................32

6.7. RESTART OF THE PELLET BURNER OPERATION. .......................................................................32

6.8. DESCRIPTION OF THE TEMPERATURE STICKERS FUNCTION FOR MONITORING OF THE

SYSTEM’S CONDITION. ..................................................................................................................................33

6.9. CLEANING AND MAINTENANCE OF A PELLET BURNER FROM SERIES „GP XX SC”. ...............34

6.10. USER INTRODUCTION WITH THE MAINTENANCE AND ADJUSTMENTS PROCEDURES OF A

PELLET BURNER FROM SERIES „GP XX SC”. .............................................................................................35

6.11. SAFETY AND UNPREDICTED RISKS. .........................................................................................36

UNPREDICTED RISKS. .................................................................................................................................... 36

6.12. COMPLETION OF THE BURNER’S WARRANTY CARD. ............................................................36

6.13. ACTIONS AFTER EXPIRY OF THE LIFE CYCLE OF A PELLET BURNER FROM SERIES „GP
XX SC”. 36

7. FAILURES AND TROUBLESHOOTING. ................................................................................................37

8. WIRING DIAGRAM OF AN AUTOMATED PELLET BURNER FROM SERIES „GP XX SC”. ..................... 42

WARRANTY CONDITIONS ............................................................................................................................... 44

Pellet burner GP xx sc 3

1. USERS SAFETY INFORMATION.

The manual for installation, operation and maintenance of the automated pellet burner from
series “GP xx sc” is designated for end users and authorized servicing specialists.

The users must know that:

 All activities regarding installation of the pellet burner should be performed only by an

authorized installers, which have acquired legal rights by the legal authorities;

 All activities regarding the electrical installation must be performed only by electrical-

technicians;

 The primary technical initialization to operation, including visual check of the entire

heating installation, adjustments and start of the pellet burner must be performed by a
person that is authorized by the manufacturer.

Please observe the following conditions during installation, start, adjustment and initialization
to operation of the automated pellet burner from series „GP xx sc”:

 All legal provisions regarding safety;
 All legal provisions regarding environment protection;
 Provisions regarding installation, start and adjustment;
 All harmonized provisions of the European Union, applicable for your country;

Please strictly observe the presented safety instructions, in order to avoid any risks or harms
to people, properties and environmental polluting.

Please pay attention to the following symbols in the present manual book:

Danger
This symbol warns the users about possible health risks.

Warning
This symbol warns the users about possible risks and harms to properties and
environment.

Information
This symbol presents texts with additional information for the users.

The current manual book uses notation „GP xx sc”, which includes the pellet

burner models "GP 20_18 sc” with heating output of 18kW, “GP 25 sc” with
heating output 25kW and pellet burner “GP 32 sc” with installed heating output
of 32kW.

For your personal safety and before taking any actions regarding the

appliance installation and operation, it is highly recommended to read
carefully this manual book. Non-compliance to the instructions presented
below might lead to fatal consequences, for which the manufacture company
will not be responsible.

Pellet burner GP xx sc 4

2. DESCRIPTION AND ADVANTAGES OF THE AUTOMATED PELLET BURNER
„GP XX SC”.

Type designation of pellet burner’s series: „GP 20_18 sc”

Example GP 20 18 sc

Pellet burner trade name

Nominal heating output *, kW

Pellet burner with self-cleaning

* Similar to other models of pellet burners „GP 25 sc” and „GP 32 sc”.

The automated modulating pellet burner from series “GP xx fsc” utilizing wood pellets is
designated for mounting to hot water boilers and other appliances. The burner utilizes wood
pellets and other types of biomass, which are described below, as the generated heat energy
is adopted by the boiler body’s heat exchanging surfaces, to which it is mounted or by other
heat energy consuming appliances.

The pellet burner from series „GP xx sc” delivery kit consists of:

 Main module – 1pc;
 Fuel transport auger – 1pc;
 Flexible pipe – 1pc, with locking brackets – 2 pcs;
 Main module package – 1pc;
 Fuel transport auger package – 1pc;
 Manual for installation, operation and maintenance of a pellet burner from series

„GP xx sc” – 1pc.

The automated pellet burner from series „GP xx sc” can utilize wood pellets with diameter Ø
6-8mm, from classes A1, A2 and B according to standard EN ISO 17225-2:2014, or
categories A, AB, B, BC and C according to the manufacture company’s classification.

The pellet burner from series „GP xx sc” is equipped with:

 Microprocessor controller managing the burner’s modules;
 Display panel with keyboard, used to manage the burner’s modules;
 Fan for fresh firing air supply equipped with Holl sensor, which controls the rotation

frequency;

 Electrical heating element used for ignition of the fuel;
 Auger for automatic fuel transportation from a hopper to the burner;
 Combustion chamber, in which an optimal burning process is realized;
 Photic sensor for dynamic control of the burning process;
 Reversible temperature sticker for indication of the system’s operation mode and of

the necessity for cleaning of the appliance/chimney, to which it is fixed;

 Irreversible temperature sticker for indication of registered overheating of the burner,

used also as precondition to deny a warranty claim.

The pellet burner is equipped with:

 System for automatic fuel ignition;
 System for automatic feeding of the fuel to the burner’s combustion chamber;

Pellet burner GP xx sc 5

 System for automatic cleaning of the combustion chamber
 Security system, which blocks the burner in case the fuel feeding inlet pipe has been

overheated, as a result from emergency situations;

 Photic sensor for dynamic control of the burning process;
 System for modulation of the firing air flow rate during the process of initial fuel

ignition;

 System for modulation of its operation mode, providing optimal operation modes and

low fuel consumption;

 Availability to perform final combustion followed by blowing, through a defined period

of time, for cleaning purposes and for new automatic restart.

Advantages of the pellet burner:

 The burner is designated for biomass utilization, which makes it ecologically clean

and does not contribute to environment polluting and to planet’s global warming;

 It is used to replace the fuel type in boilers for utilization of wood and coal;
 Modern and multifunctional microprocessor control module, made in Sweden,

providing precise operation of the burner’s process components, through parameters
adjustment;

 Automatic testing of the system’s functions;
 Five levels for modulation of the heating output through quick access, as they can be

easily changed by the users;

 Automatic modulation – adjustment of the needed fresh air quantity, according to the

heating output chosen by the user;

 Automatic self-adjustment of the system, according to the transport auger’s feeding

rate / productivity, to specific climate conditions and to the fuel’s caloricity;

 Indication of the heat carrier (or water) temperature in the boiler;
 Availability to save the current adjustments and to restore the factory settings;
 Passwords for limiting the access to certain levels, to parameters for the users and

for the servicing staff;

 Availability for operation with temperature sensor, boiler and room thermostats;
 Special measures to increase the reliability and the safety of the product;
 Independence from the quality of the burned wood pellets with diameter Ø 6-8mm;
 Availability to choose from 4 types of adjustments, depending on the quality of the

burned pellets, at stable efficiency;

 Unique automatic cleaning of the combustion chamber, through mechanical scraping

of the combustion chamber’s fire-grate;

 Availability to control a circulations pump;
 Availability to control a flue extraction fan;
 Easier servicing through the control module’s function – “History errors”;
 The burner is equipped with system for automatic fuel ignition;
 Simplified installation and adjustment of the burner, which accelerates the installer’s

work;

 High efficiency;
 Low harmful emission;
 Automatic fuel feeding from a hopper, which can be build according to the local

conditions (it is not included in the burner’s standard delivery kit);

 Simplified maintenance;
 Minimum operation costs.

Pellet burner GP xx sc 6

20

+1100

3. TECHNICAL DATA OF THE PELLET BURNER FROM SERIES „GP XX SC”.

The technical data of the automated pellet burner from series „GP xx sc”, operating with
wood pellets, is presented in Table 3.1.

Table 3.1. Technical parameters of the automated pellet burner from series „GP xx sc”,

operating with wood pellets.

PARAMETER DIMENSION VALUE

Burner model - GP 20_18 sc GP 25 sc

GP 32 sc
Nominal heating output kW 18 25 32
Heating output adjustment range kW 7-18 7-25 10-32

Used fuel - Wood pellets
Wood pellets classes according to

- A1, A2 and B
standard EN ISO 17225-2:2014
Used pellets categories (according to

- A, AB, B, BC and C
the manufacture company’s
classification)

The quantity depends on the pellets ash

Wastes after complete fuel burning Ash

content and on the burner’s operation

mode

The automated pellet burner from series „GP xx sc” is designated for utilization of

wood pellets complying with the classification of standard EN ISO 17225-2:2014,
classes A1, A2 and B, and also with the developed classification by the
manufacture company.

The dimensions and technical parameters of the automated pellet burner from series „GP xx
sc” are presented in Table 3.2.

Table 3.2. Dimensions and technical parameters of an automated pellet burner from series

„GP xx sc”.

PARAMETER DIMENSION VALUE

Model - GP 20_18 sc GP 25 sc GP 32 sc

Main module kg 20 20

Weight

Fuel feeding

kg 8.5 8.5 8.5

auger
Overall
dimensions
(WхLхH)

Main module mm 250х705х488

Fuel feeding

auger

mm 184x1520x107

Power supply voltage - L1, N, PE, 50Hz; 230VAC;

Electrical
consumption

In nominal

mode

In ignition

A 0.2 0.2 0.2

A 4.5 4.5 4.5

mode
Electrical power W

<100

(with ignition)

Electrical protection - IP20

Pellet burner GP xx sc 7

With the adoption of the new standard for wood pellets (EN ISO 17225-2) in 2014 there are





















introduced a new classes for wood pellets used in domestic heating boilers (Table 3.3.).

Table 3.3. Standard for wood pellets EN ISO 17225-2:2014.

Parameter Dimension Class A1 Class A2 Class B

Length (L) mm 3,15 ≤ L≤ 40 3,15 ≤ L≤ 40 3,15 ≤ L≤ 40
Diameter (D) mm 6±1

8±1

Moisture (М) % < 10 < 10 < 10
Ash (A), dry % < 0,7 < 1,2 < 2,0

Buck density (BD) kg/m3 > 600 > 600 > 600
Mechanical durability (DU) % > 97.5 > 97.5 > 96.5
Net caloricity (Q) MJ/kg

kWh/kg
Chlorine Cl % < 0,02 < 0,02 < 0,03
Nitrogen (N) % < 0,3 < 0,5 < 1,0
Sulphur (S) % < 0,04 < 0,05 < 0,05
Arsenic (As) mg/kg < 1 < 1 < 1
Cadmium (Cd) mg/kg < 0.5 < 0.5 < 0.5
Chromium (Cr) mg/kg < 10 < 10 < 10
Copper (Cu) mg/kg < 10 < 10 < 10
Lead (Pb) mg/kg < 10 < 10 < 10
Mercury (Hg) mg/kg < 0.1 < 0.1 < 0.1
Nickel (Ni) mg/kg < 10 < 10 < 10
Zinc (Zn) mg/kg < 100 < 100 < 100

Wood pellets classification, developed and applied by the manufacture company, depending
on their physical properties is presented in Table 3.4.

Table 3.4. Wood pellets classification, developed and applied by the manufacture company,

depending on their physical properties.

PELLETS CATEGORY AD DU

A

AB

B

BC

C

CD

D

DE

E

EF

where:

Ad - ash content of dry mass, %;
DU - mechanical resistance, %.

d

A

d

A

d

A

d

A

> 16,5

> 4.6

%6.0
%6.0

%0.16.0 dA
%0.16.0 dA

%0.3
%0.3

%0.2%0.1 dA
%0.2%0.1 dA
%0.3%0.2 dA
%0.3%0.2 dA

DU
DU
DU
DU
DU
DU
DU
DU
DU
DU

6±1
8±1

> 16,5

> 4.6

6±1
8±1

> 16,5

> 4.6

%0.97
%0.97
%0.97
%0.97
%0.97
%0.97
%0.97
%0.97
%0.97
%0.97

Pellet burner GP xx sc 8

4. CONSTRUCTION DESCRIPTION OF THE PELLET BURNER “GP XX SC”.

4.1. GENERAL CONDITIONS.

The main part from the construction of a pellet burner from series „GP xx sc” is the main
module, which consists of:

 Combustion chamber, which forms conditions for optimal burning process and is

made of high quality stainless steel;

 Combustion chamber’s fire-grate;
 System for automatic cleaning of the combustion chamber;
 Air distribution tract, which provides equal firing air feeding and also cooling of the

burner’s components;

 Heating element, which ignites the fuel, positioned under the tilted part of the

combustion chamber’s fire-grate;

 Firing air feeding fan, equipped with sensor for controlling of the rotation frequency

and also for adjustments;

 Photic sensor, which monitors the burning process, mounted on the burner’s side and

with availability for easy cleaning;

 Emergency temperature sensor for protection from the so called “back fire” in the

main module’s pellets feeding pipe;

 Control module, which monitors and manages the burner’s operation;
 Display panel with keyboard, which visualizes the burner’s operation mode and is

used to perform the necessary adjustments;

 Connector for the fuel transport auger, used to supply the auger with electrical power;
 Flexible pipe, made of special transparent high temperature resistant material (in

case of fire it does not separate toxic substances), used to connect the auger and the
main module of the burner.

Figure 4.1 presents a view of the main modules of a pellet burner from series „GP xx sc”.

Pellet burner GP xx sc 9

fire”

protection

keyboard

)

Interface panel
(display +

Photic sensor

Main module
housing

Socket for power
supply and
control of the
transport auger

Figure 4.1. View of the main module of a pellet burner from series „GP xx sc”.

Pellets feeding
inlet pipe to
combustion
chamber

Emergency
sensor for “back

Flange for
mounting of the
main module to
an appliance

Combustion
chamber’s
fire-grate

Combustion
chamber

Pellet burner GP xx sc 10

5. MOUNTING AND INSTALLATION OF THE PELLET BURNER.

5.1. MAIN REQUIREMENTS FOR INSTALLATION OF A PELLET BURNER „GP XX

SC”.

The following requirements must be observed during installation of a pellet burner from
series „GP xx sc”:

 The burner must be positioned in a way providing enough free space for its cleaning

and maintenance;

 The burner must be mounted to appliance (hot water boiler, or other heat energy

consumer) in a way providing availability for easy maintenance and cleaning of the
appliance;

 It is not allowed to mount the burner to appliance, which has been installed in living

premises, including corridors;

 The installation and mounting of the burner to appliance must be performed only by a

qualified technician;

 The installation and maintenance of the automated pellet burner must be performed

by specialized companies which have acquired legal rights for such activities;

 The automated pellet burner from series „GP xx sc” must be connected to the

electrical supply installation only by an authorized electrical technician;

 Before initiation of the burner to operation, the heat energy consuming appliance’s

operational condition must be checked;

 The burner attendance must be performed only by adult persons, which are well

familiar with the appliance’s manual for operation.

The mounting of the burner to a boiler (consumer-appliance) can be performed

through bolts (or studs) and nuts. The tightening of the burner has to be
performed by a tool (for example wrench). It is not allowed to fix it through
handles or others. The fixing and dismounting operations of the burner must be
performed by a qualified person equipped with proper tools.

5.2. INSTALLATION OF THE PELLET BURNER.

The installation of the pellet burner from series „GP xx sc” to appliance requires preliminary
prepared technical project, complying with the acting provisions and regulations:

 In case the consuming appliance is a hot water boiler, then the requirements

presented in standard EN 303-5:2012 - "Heating boilers. Part 5: Heating boilers for
solid fuels, manually and automatically stoked nominal heat output of up to 500 kW.
Terminology, requirements, testing and marking.;

 In case the heat energy consuming appliance is not a hot water boiler, then the

requirements presented in the relevant standards for such type of appliances must be
observed;

 Fire safety provisions;
 About the electrical supply network – EN 60335-1/1997 – “Securing of electrical

domestic appliances”.

When installing a pellet burner to a hot water boiler, please observe the relevant

chimney draught requirements, presented in the boiler’s technical data sheet.

Pellet burner GP xx sc 11

5.3. OVERALL DIMENSIONS OF THE BURNER’S MAIN MODULE.

Figure 5.1 and 5.2 present the overall dimensions of the burner’s main module, which have
to be taken in mind during the mounting and installation of the appliance.

Figure 5.1. Main module’s overall dimensions of a pellet burner from series „GP xx sc”.

Figure 5.2. Overall dimensions of the burner’s main module.

Pellet burner GP xx sc 12

5.4. POSITIONING AND MOUNTING OF THE BURNER’S MODULES.

The main module of a pellet burner from series „GP xx sc” has to be mounted horizontally to
the appliance, which will consume the heat energy generated by the fuel burning. Depending
on the appliance type a technical evaluation has to be performed in advance, regarding the
burner’s main module position, in order to achieve reliable operation, easy cleaning,
maintenance and servicing.

The burner’s main module has to be mounted to the heat energy consuming appliance by
using the attached sealing. The fuel transport auger has to be positioned near to the burner,
in order to ensure the connection between it and the main module through the flexible tube,
through which the fuel transits. It is also recommended that the tilting angle between the
transport auger and the horizontal plane is fixed to 45o, which will provide optimal operation
of the auger’s electric motor and of the burning process.

In order to ensure optimal operational conditions of the fuel transport auger it is
recommended to use a pellet hopper – produced by the burner’s
manufacture company. This hopper is not included in the standard delivery kit of
the pellet burners from series „GP xx sc”.

Change of the auger’s tilting angle leads to changes in the fuel consumption and

respectively to the burner’s heating output:

- Decreasing the auger’s tilting angle leads to increased fuel consumption,

respectively to increased heating output;

- Increasing the auger’s tilting angle leads to decreased fuel consumption,

respectively to decreased heating output.

Figure 5.3 presents a scheme for installation and positioning of the fuel transport auger.

Figure 5.3. Scheme for installation and positioning of the fuel feeding auger.

Fuel Hopper”

45о

The auger on the scheme is equipped with metal support bar, which is optional
equipment to the burner’s delivery kit. The auger’s axis has to be positioned at
45o angle relative to the horizontal plane.

Pellet burner GP xx sc 13

5.5. INFORMATION ABOUT INSTALLATION AVAILABILITIES OF PELLET BURNER

„GP XX SC” AND ITS CO-OPERATION WITH HOT WATER BOILERS.

The automated pellet burner from series „GP xx sc” is a standalone module (requires power
supply and signal – assignment for operation), which can be mounted to a heat energy
consuming appliance. The practice shows that the heat energy consuming appliance is most
frequently a hot water boiler, used in local heating installation. The manufacture company
has accomplished continues tests for compatibility, reliability and efficiency of the burner in
co-operation with series of popular hot water boilers. Depending on the hot water boiler
model additional transition modules and components might be used, in order to improve the
system’s performance that is consisting of a pellet burner and a hot water boiler, and to
increase its efficiency and reliability.

Pellet burner GP xx sc 14